Printhead integrated circuit with an ink ejecting surface

ABSTRACT

Provided is a printhead integrated circuit defining an external surface having a number of ink ejection ports operatively directed at a printing medium. The surface includes a plurality of petal formations radially positioned about each ink ejection port, and a plurality of actuators, each located behind a petal formation distal from said port. The surface also includes a plurality of heater structures each connected to an actuator, so that heating of the structures via an electrical current produces expansion in said actuators which urges the formations into a chamber below the surface.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation of U.S. application Ser. No. 11/442,160 filed May 30, 2006, now issued U.S. Pat. No. 7325904, which is a continuation of U.S. application Ser. No. 11/055,203 filed Feb. 11, 2005, now issued U.S. Pat. No. 7,086,721, which is a continuation of U.S. application Ser. No. 10/808,582 filed Mar. 25, 2004, now issued U.S. Pat. No. 6,886,918, which is a Continuation of U.S. application Ser. No. 09/854,714 filed May 14, 2001, now issued U.S. Pat. No. 6,712,986, which is a Continuation of U.S. application Ser. No. 09/112,806, filed Jul. 10, 1998, now issued U.S. Patent No. 6,247,790. The entire contents of are herein incorporated by reference.

CROSS REFERENCES TO RELATED APPLICATIONS

The following Australian provisional patent applications are hereby incorporated by cross-reference. For the purposes of location and identification, US patent applications identified by their US patent application serial numbers (USSN) are listed alongside the Australian applications from which the US patent applications claim the right of priority.

U.S. Pat./ CROSS-REFERENCED PATENT APPLICATION AUSTRALIAN (Claiming Right of Priority from Provisional Patent Australian Provisional Application No. Application)HZ,1/32 PO7991 6750901 PO8505 6476863 PO7988 6788336 PO9395 6322181 PO8017 6597817 PO8014 6227648 PO8025 6727948 PO8032 6690419 PO7999 6727951 PO8030 6196541 PO7997 6195150 PO7979 6362868 PO7978 6831681 PO7982 6431669 PO7989 6362869 PO8019 6472052 PO7980 6356715 PO8018 6894694 PO7938 6636216 PO8016 6366693 PO8024 6329990 PO7939 6459495 PO8501 6137500 PO8500 6690416 PO7987 7050143 PO8022 6398328 PO8497 7110024 PO8020 6431704 PO8504 6879341 PO8000 6415054 PO7934 6665454 PO7990 6542645 PO8499 6486886 PO8502 6381361 PO7981 6317192 PO7986 6850274 PO7983 09/113054 PO8026 6646757 PO8028 6624848 PO9394 6357135 PO9397 6271931 PO9398 6353772 PO9399 6106147 PO9400 6665008 PO9401 6304291 PO9403 6305770 PO9405 6289262 PP0959 6315200 PP1397 6217165 PP2370 6786420 PO8003 6350023 PO8005 6318849 PO8066 6227652 PO8072 6213588 PO8040 6213589 PO8071 6231163 PO8047 6247795 PO8035 6394581 PO8044 6244691 PO8063 6257704 PO8057 6416168 PO8056 6220694 PO8069 6257705 PO8049 6247794 PO8036 6234610 PO8048 6247793 PO8070 6264306 PO8067 6241342 PO8001 6247792 PO8038 6264307 PO8033 6254220 PO8002 6234611 PO8068 6302528 PO8062 6283582 PO8034 6239821 PO8039 6338547 PO8041 6247796 PO8004 6557977 PO8037 6390603 PO8043 6362843 PO8042 6293653 PO8064 6312107 PO9389 6227653 PO9391 6234609 PP0888 6238040 PP0891 6188415 PP0890 6227654 PP0873 6209989 PP0993 6247791 PP0890 6336710 PP1398 6217153 PP2592 6416167 PP2593 6243113 PP3991 6283581 PP3987 6247790 PP3985 6260953 PP3983 6267469 PO7935 6224780 PO7936 6235212 PO7937 6280643 PO8061 6284147 PO8054 6214244 PO8065 6071750 PO8055 6267905 PO8053 6251298 PO8078 6258285 PO7933 6225138 PO7950 6241904 PO7949 6299786 PO8060 6866789 PO8059 6231773 PO8073 6190931 PO8076 6248249 PO8075 6290862 PO8079 6241906 PO8050 6565762 PO8052 6241905 PO7948 6451216 PO7951 6231772 PO8074 6274056 PO7941 6290861 PO8077 6248248 PO8058 6306671 PO8051 6331258 PO8045 6110754 PO7952 6294101 PO8046 6416679 PO9390 6264849 PO9392 6254793 PP0889 6235211 PP0887 6491833 PP0882 6264850 PP0874 6258284 PP1396 6312615 PP3989 6228668 PP2591 6180427 PP3990 6171875 PP3986 6267904 PP3984 6245247 PP3982 6315914 PP0895 6231148 PP0869 6293658 PP0887 6614560 PP0885 6238033 PP0884 6312070 PP0886 6238111 PP0877 6378970 PP0878 6196739 PP0883 6270182 PP0880 6152619 PO8006 6087638 PO8007 6340222 PO8010 6041600 PO8011 6299300 PO7947 6067797 PO7944 6286935 PO7946 6044646 PP0894 6382769

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

FIELD OF THE INVENTION

The present invention relates to the field of inkjet printing and, in particular, discloses an inverted radial back-curling thermoelastic ink jet printing mechanism.

BACKGROUND OF THE INVENTION

Many different types of printing mechanisms have been invented, a large number of which are presently in use. The known forms of printers have a variety of methods for marking the print media with a relevant marking media. Commonly used forms of printing include offset printing, laser printing and copying devices, dot matrix type impact printers, thermal paper printers, film recorders, thermal wax printers, dye sublimation printers and ink jet printers both of the drop on demand and continuous flow type. Each type of printer has its own advantages and problems when considering cost, speed, quality, reliability, simplicity of construction and operation etc.

In recent years the field of ink jet printing, wherein each individual pixel of ink is derived from one or more ink nozzles, has become increasingly popular primarily due to its inexpensive and versatile nature.

Many different techniques of ink jet printing have been invented. For a survey of the field, reference is made to an article by J Moore, “Non-Impact Printing: Introduction and Historical Perspective”, Output Hard Copy Devices, Editors R Dubeck and S Sherr, pages 207-220 (1988).

Ink Jet printers themselves come in many different forms. The utilization of a continuous stream of ink in ink jet printing appears to date back to at least 1929 wherein U.S. Pat. No. 1,941,001 by Hansell discloses a simple form of continuous stream electro-static ink jet printing.

U.S. Pat. No. 3,596,275 by Sweet also discloses a process of a continuous ink jet printing including a step wherein the ink jet stream is modulated by a high frequency electro-static field so as to cause drop separation. This technique is still utilized by several manufacturers including Elmjet and Scitex (see also U.S. Pat. No. 3,373,437 by Sweet et al).

Piezoelectric ink jet printers are also one form of commonly utilized ink jet printing device. Piezoelectric systems are disclosed by Kyser et. al. in U.S. Pat. No. 3,946,398 (1970) which utilizes a diaphragm mode of operation, by Zolten in U.S. Pat. No. 3,683,212 (1970) which discloses a squeeze mode form of operation of a piezoelectric crystal, Stemme in U.S. Pat. No. 3,747,120 (1972) which discloses a bend mode of piezoelectric operation, Howkins in U.S. Pat. No. 4,459,601 which discloses a piezoelectric push mode actuation of the ink jet stream and Fischbeck in U.S. Pat. No. 4,584,590 which discloses a shear mode type of piezoelectric transducer element.

Recently, thermal ink jet printing has become an extremely popular form of ink jet printing. The ink jet printing techniques include those disclosed by Endo et al in GB 2007162 (1979) and Vaught et al in U.S. Pat. No. 4,490,728. Both the aforementioned references disclose ink jet printing techniques which rely on the activation of an electrothermal actuator which results in the creation of a bubble in a constricted space, such as a nozzle, which thereby causes the ejection of ink from an aperture connected to the confined space onto a relevant print media. Printing devices utilizing the electro-thermal actuator are manufactured by manufacturers such as Canon and Hewlett Packard.

As can be seen from the foregoing, many different types of printing technologies are available. Ideally, a printing technology should have a number of desirable attributes. These include inexpensive construction and operation, high speed operation, safe and continuous long term operation etc. Each technology may have its own advantages and disadvantages in the areas of cost, speed, quality, reliability, power usage, simplicity of construction and operation, durability and consumables.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the present invention, there is provided an inkjet printhead for printing on a media substrate, the printhead comprising:

a wafer substrate defining a plurality of nozzle chambers for storing ink to be ejected, each of the nozzle chambers having an outer wall that faces the media substrate during use, the wall having an ink ejection port and at least one actuator for moving the ink ejection port away from the media substrate to eject ink from the corresponding nozzle chamber via the ink ejection port.

By incorporating one or more actuators into the outer wall so that the ejection port can be depressed into the nozzle chamber, there are no ejection actuators in the interior of the chamber to impede ink refill. Furthermore, as the outer wall returns to its quiescent configuration after ejection, it draws ink into the chamber as well as the surface tension of the meniscus at the port.

Preferably there is a plurality of actuators in the wall.

The actuators can include a surface which bends inwards away from the centre of the nozzle chamber upon actuation. The actuators are preferably actuated by means of a thermal actuator device. The thermal actuator device may comprise a conductive resistive heating element encased within a material having a high coefficient of thermal expansion. The element can be serpentine to allow for substantially unhindered expansion of the material. The actuators are preferably arranged radially around the nozzle rim.

The actuators can form a membrane between the nozzle chamber and an external atmosphere of the arrangement and the actuators bend away from the external atmosphere to cause an increase in pressure within the nozzle chamber thereby initiating a consequential ejection of ink from the nozzle chamber. The actuators can bend away from a central axis of the nozzle chamber.

The nozzle arrangement can be formed on the wafer substrate utilizing micro-electro mechanical techniques and further can comprise an ink supply channel in communication with the nozzle chamber. The ink supply channel may be etched through the wafer. The nozzle arrangement may include a series of struts which support the nozzle rim.

The arrangement can be formed adjacent to neighbouring arrangements so as to form a pagewidth printhead.

BRIEF DESCRIPTION OF THE DRAWINGS

Notwithstanding any other forms which may fall within the scope of the present invention, preferred forms of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

FIGS. 1-3 are schematic sectional views illustrating the operational principles of the preferred embodiment;

FIG. 4( a) and FIG. 4( b) are again schematic sections illustrating the operational principles of the thermal actuator device;

FIG. 5 is a side perspective view, partly in section, of a single nozzle arrangement constructed in accordance with the preferred embodiments;

FIGS. 6-13 are side perspective views, partly in section, illustrating the manufacturing steps of the preferred embodiments;

FIG. 14 illustrates an array of ink jet nozzles formed in accordance with the manufacturing procedures of the preferred embodiment;

FIG. 15 provides a legend of the materials indicated in FIGS. 16 to 23; and

FIG. 16 to FIG. 23 illustrate sectional views of the manufacturing steps in one form of construction of a nozzle arrangement in accordance with the invention.

DESCRIPTION OF PREFERRED AND OTHER EMBODIMENTS

In the preferred embodiment, ink is ejected out of a nozzle chamber via an ink ejection port using a series of radially positioned thermal actuator devices that are arranged about the ink ejection port and are activated to pressurize the ink within the nozzle chamber thereby causing the ejection of ink through the ejection port.

Turning now to FIGS. 1, 2 and 3, there is illustrated the basic operational principles of the preferred embodiment. FIG. 1 illustrates a single nozzle arrangement 1 in its quiescent state. The arrangement 1 includes a nozzle chamber 2 which is normally filled with ink so as to form a meniscus 3 in an ink ejection port 4. The nozzle chamber 2 is formed within a wafer 5. The nozzle chamber 2 is supplied with ink via an ink supply channel 6 which is etched through the wafer 5 with a highly isotropic plasma etching system. A suitable etcher can be the Advance Silicon Etch (ASE) system available from Surface Technology Systems of the United Kingdom.

A top of the nozzle arrangement 1 includes a series of radially positioned actuators 8, 9. These actuators comprise a polytetrafluoroethylene (PTFE) layer and an internal serpentine copper core 17. Upon heating of the copper core 17, the surrounding PTFE expands rapidly resulting in a generally downward movement of the actuators 8, 9. Hence, when it is desired to eject ink from the ink ejection port 4, a current is passed through the actuators 8, 9 which results in them bending generally downwards as illustrated in FIG. 2. The downward bending movement of the actuators 8, 9 results in a substantial increase in pressure within the nozzle chamber 2. The increase in pressure in the nozzle chamber 2 results in an expansion of the meniscus 3 as illustrated in FIG. 2.

The actuators 8, 9 are activated only briefly and subsequently deactivated. Consequently, the situation is as illustrated in FIG. 3 with the actuators 8, 9 returning to their original positions. This results in a general inflow of ink back into the nozzle chamber 2 and a necking and breaking of the meniscus 3 resulting in the ejection of a drop 12. The necking and breaking of the meniscus 3 is a consequence of the forward momentum of the ink associated with drop 12 and the backward pressure experienced as a result of the return of the actuators 8, 9 to their original positions. The return of the actuators 8,9 also results in a general inflow of ink from the channel 6 as a result of surface tension effects and, eventually, the state returns to the quiescent position as illustrated in FIG. 1.

FIGS. 4( a) and 4(b) illustrate the principle of operation of the thermal actuator. The thermal actuator is preferably constructed from a material 14 having a high coefficient of thermal expansion. Embedded within the material 14 are a series of heater elements 15 which can be a series of conductive elements designed to carry a current. The conductive elements 15 are heated by passing a current through the elements 15 with the heating resulting in a general increase in temperature in the area around the heating elements 15. The position of the elements 15 is such that uneven heating of the material 14 occurs. The uneven increase in temperature causes a corresponding uneven expansion of the material 14. Hence, as illustrated in FIG. 4( b), the PTFE is bent generally in the direction shown.

In FIG. 5, there is illustrated a side perspective view of one embodiment of a nozzle arrangement constructed in accordance with the principles previously outlined. The nozzle chamber 2 is formed with an isotropic surface etch of the wafer 5. The wafer 5 can include a CMOS layer including all the required power and drive circuits. Further, the actuators 8, 9 each have a leaf or petal formation which extends towards a nozzle rim 28 defining the ejection port 4. The normally inner end of each leaf or petal formation is displaceable with respect to the nozzle rim 28. Each activator 8, 9 has an internal copper core 17 defining the element 15. The core 17 winds in a serpentine manner to provide for substantially unhindered expansion of the actuators 8, 9. The operation of the actuators 8, 9 is as illustrated in FIG. 4( a) and FIG. 4( b) such that, upon activation, the actuators 8 bend as previously described resulting in a displacement of each petal formation away from the nozzle rim 28 and into the nozzle chamber 2. The ink supply channel 6 can be created via a deep silicon back edge of the wafer 5 utilizing a plasma etcher or the like. The copper or aluminium core 17 can provide a complete circuit. A central arm 18 which can include both metal and PTFE portions provides the main structural support for the actuators 8, 9.

Turning now to FIG. 6 to FIG. 13, one form of manufacture of the nozzle arrangement 1 in accordance with the principles of the preferred embodiment is shown. The nozzle arrangement 1 is preferably manufactured using microelectromechanical (MEMS) techniques and can include the following construction techniques:

As shown initially in FIG. 6, the initial processing starting material is a standard semi-conductor wafer 20 having a complete CMOS level 21 to a first level of metal. The first level of metal includes portions 22 which are utilized for providing power to the thermal actuators 8, 9.

The first step, as illustrated in FIG. 7, is to etch a nozzle region down to the silicon wafer 20 utilizing an appropriate mask.

Next, as illustrated in FIG. 8, a 2 μm layer of polytetrafluoroethylene (PTFE) is deposited and etched so as to define vias 24 for interconnecting multiple levels.

Next, as illustrated in FIG. 9, the second level metal layer is deposited, masked and etched to define a heater structure 25. The heater structure 25 includes via 26 interconnected with a lower aluminium layer.

Next, as illustrated in FIG. 10, a further 2 μm layer of PTFE is deposited and etched to the depth of 1 μm utilizing a nozzle rim mask to define the nozzle rim 28 in addition to ink flow guide rails 29 which generally restrain any wicking along the surface of the PTFE layer. The guide rails 29 surround small thin slots and, as such, surface tension effects are a lot higher around these slots which in turn results in minimal outflow of ink during operation.

Next, as illustrated in FIG. 11, the PTFE is etched utilizing a nozzle and actuator mask to define a port portion 30 and slots 31 and 32.

Next, as illustrated in FIG. 12, the wafer is crystallographically etched on a <111> plane utilizing a standard crystallographic etchant such as KOH. The etching forms a chamber 33, directly below the port portion 30.

In FIG. 13, the ink supply channel 34 can be etched from the back of the wafer utilizing a highly anisotropic etcher such as the STS etcher from Silicon Technology Systems of United Kingdom. An array of ink jet nozzles can be formed simultaneously with a portion of an array 36 being illustrated in FIG. 14. A portion of the printhead is formed simultaneously and diced by the STS etching process. The array 36 shown provides for four column printing with each separate column attached to a different colour ink supply channel being supplied from the back of the wafer. Bond pads 37 provide for electrical control of the ejection mechanism.

In this manner, large pagewidth printheads can be fabricated so as to provide for a drop-on-demand ink ejection mechanism.

One form of detailed manufacturing process which can be used to fabricate monolithic ink jet printheads operating in accordance with the principles taught by the present embodiment can proceed utilizing the following steps:

1. Using a double-sided polished wafer 60, complete a 0.5 micron, one poly, 2 metal CMOS process 61. This step is shown in FIG. 16. For clarity, these diagrams may not be to scale, and may not represent a cross section though any single plane of the nozzle. FIG. 15 is a key to representations of various materials in these manufacturing diagrams, and those of other cross referenced ink jet configurations.

2. Etch the CMOS oxide layers down to silicon or second level metal using Mask 1. This mask defines the nozzle cavity and the edge of the chips. This step is shown in FIG. 16.

3. Deposit a thin layer (not shown) of a hydrophilic polymer, and treat the surface of this polymer for PTFE adherence.

4. Deposit 1.5 microns of polytetrafluoroethylene (PTFE) 62.

5. Etch the PTFE and CMOS oxide layers to second level metal using Mask 2. This mask defines the contact vias for the heater electrodes. This step is shown in FIG. 17.

6. Deposit and pattern 0.5 microns of gold 63 using a lift-off process using Mask 3. This mask defines the heater pattern. This step is shown in FIG. 18.

7. Deposit 1.5 microns of PTFE 64.

8. Etch 1 micron of PTFE using Mask 4. This mask defines the nozzle rim 65 and the rim at the edge 66 of the nozzle chamber. This step is shown in FIG. 19.

9. Etch both layers of PTFE and the thin hydrophilic layer down to silicon using Mask 5. This mask defines a gap 67 at inner edges of the actuators, and the edge of the chips. It also forms the mask for a subsequent crystallographic etch. This step is shown in FIG. 20.

10. Crystallographically etch the exposed silicon using KOH. This etch stops on <111> crystallographic planes 68, forming an inverted square pyramid with sidewall angles of 54.74 degrees. This step is shown in FIG. 21.

11. Back-etch through the silicon wafer (with, for example, an ASE Advanced Silicon Etcher from Surface Technology Systems) using Mask 6. This mask defines the ink inlets 69 which are etched through the wafer. The wafer is also diced by this etch. This step is shown in FIG. 22.

12. Mount the printheads in their packaging, which may be a molded plastic former incorporating ink channels which supply the appropriate color ink to the ink inlets 69 at the back of the wafer.

13. Connect the printheads to their interconnect systems. For a low profile connection with minimum disruption of airflow, TAB may be used. Wire bonding may also be used if the printer is to be operated with sufficient clearance to the paper.

14. Fill the completed print heads with ink 70 and test them. A filled nozzle is shown in FIG. 23.

The presently disclosed ink jet printing technology is potentially suited to a wide range of printing systems including: color and monochrome office printers, short run digital printers, high speed digital printers, offset press supplemental printers, low cost scanning printers high speed pagewidth printers, notebook computers with inbuilt pagewidth printers, portable color and monochrome printers, color and monochrome copiers, color and monochrome facsimile machines, combined printer, facsimile and copying machines, label printers, large format plotters, photograph copiers, printers for digital photographic “minilabs”, video printers, PHOTO CD (PHOTO CD is a registered trade mark of the Eastman Kodak Company) printers, portable printers for PDAs, wallpaper printers, indoor sign printers, billboard printers, fabric printers, camera printers and fault tolerant commercial printer arrays.

It would be appreciated by a person skilled in the art that numerous variations and/or modifications may be made to the present invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects to be illustrative and not restrictive.

Ink Jet Technologies

The embodiments of the invention use an ink jet printer type device. Of course many different devices could be used. However presently popular ink jet printing technologies are unlikely to be suitable.

The most significant problem with thermal ink jet is power consumption. This is approximately 100 times that required for high speed, and stems from the energy-inefficient means of drop ejection. This involves the rapid boiling of water to produce a vapor bubble which expels the ink. Water has a very high heat capacity, and must be superheated in thermal ink jet applications. This leads to an efficiency of around 0.02%, from electricity input to drop momentum (and increased surface area) out.

The most significant problem with piezoelectric ink jet is size and cost. Piezoelectric crystals have a very small deflection at reasonable drive voltages, and therefore require a large area for each nozzle. Also, each piezoelectric actuator must be connected to its drive circuit on a separate substrate. This is not a significant problem at the current limit of around 300 nozzles per printhead, but is a major impediment to the fabrication of pagewidth printheads with 19,200 nozzles.

Ideally, the ink jet technologies used meet the stringent requirements of in-camera digital color printing and other high quality, high speed, low cost printing applications. To meet the requirements of digital photography, new ink jet technologies have been created. The target features include:

low power (less than 10 Watts)

high resolution capability (1,600 dpi or more)

photographic quality output

low manufacturing cost

small size (pagewidth times minimum cross section)

high speed (<2 seconds per page).

All of these features can be met or exceeded by the ink jet systems described below with differing levels of difficulty. Forty-five different ink jet technologies have been developed by the Assignee to give a wide range of choices for high volume manufacture. These technologies form part of separate applications assigned to the present Assignee as set out in the table below under the heading Cross References to Related Applications.

The ink jet designs shown here are suitable for a wide range of digital printing systems, from battery powered one-time use digital cameras, through to desktop and network printers, and through to commercial printing systems.

For ease of manufacture using standard process equipment, the printhead is designed to be a monolithic 0.5 micron CMOS chip with MEMS post processing. For color photographic applications, the printhead is 100 mm long, with a width which depends upon the ink jet type. The smallest printhead designed is IJ38, which is 0.35 mm wide, giving a chip area of 35 square mm. The printheads each contain 19,200 nozzles plus data and control circuitry.

Ink is supplied to the back of the printhead by injection molded plastic ink channels. The molding requires 50 micron features, which can be created using a lithographically micromachined insert in a standard injection molding tool. Ink flows through holes etched through the wafer to the nozzle chambers fabricated on the front surface of the wafer. The printhead is connected to the camera circuitry by tape automated bonding.

Tables of Drop-on-Demand Ink Jets

Eleven important characteristics of the fundamental operation of individual ink jet nozzles have been identified. These characteristics are largely orthogonal, and so can be elucidated as an eleven dimensional matrix. Most of the eleven axes of this matrix include entries developed by the present assignee.

The following tables form the axes of an eleven dimensional table of ink jet types.

Actuator mechanism (18 types)

Basic operation mode (7 types)

Auxiliary mechanism (8 types)

Actuator amplification or modification method (17 types)

Actuator motion (19 types)

Nozzle refill method (4 types)

Method of restricting back-flow through inlet (10 types)

Nozzle clearing method (9 types)

Nozzle plate construction (9 types)

Drop ejection direction (5 types)

Ink type (7 types)

The complete eleven dimensional table represented by these axes contains 36.9 billion possible configurations of ink jet nozzle. While not all of the possible combinations result in a viable ink jet technology, many million configurations are viable. It is clearly impractical to elucidate all of the possible configurations. Instead, certain ink jet types have been investigated in detail. These are designated IJ01 to IJ45 above which matches the docket numbers in the table under the heading Cross References to Related Applications.

Other ink jet configurations can readily be derived from these forty-five examples by substituting alternative configurations along one or more of the 11 axes. Most of the IJ01 to IJ45 examples can be made into ink jet printheads with characteristics superior to any currently available ink jet technology.

Where there are prior art examples known to the inventor, one or more of these examples are listed in the examples column of the tables below. The IJ01 to IJ45 series are also listed in the examples column. In some cases, print technology may be listed more than once in a table, where it shares characteristics with more than one entry.

Suitable applications for the ink jet technologies include: Home printers, Office network printers, Short run digital printers, Commercial print systems, Fabric printers, Pocket printers, Internet WWW printers, Video printers, Medical imaging, Wide format printers, Notebook PC printers, Fax machines, Industrial printing systems, Photocopiers, Photographic minilabs etc.

The information associated with the aforementioned 11 dimensional matrix are set out in the following tables.

ACTUATOR MECHANISM (APPLIED ONLY TO SELECTED INK DROPS) Description Advantages Disadvantages Examples Thermal An electrothermal Large force High power Canon bubble heater heats the generated Ink carrier Bubblejet 1979 ink to above Simple limited to water Endo et al GB boiling point, construction Low patent 2,007,162 transferring No moving efficiency Xerox heater- significant heat to parts High in-pit 1990 the aqueous ink. A Fast operation temperatures Hawkins et al bubble nucleates Small chip required U.S. Pat. No. 4,899,181 and quickly forms, area required for High Hewlett- expelling the ink. actuator mechanical Packard TIJ The efficiency of stress 1982 Vaught et the process is low, Unusual al U.S. Pat. No. with typically less materials 4,490,728 than 0.05% of the required electrical energy Large drive being transformed transistors into kinetic energy Cavitation of the drop. causes actuator failure Kogation reduces bubble formation Large print heads are difficult to fabricate Piezoelectric A piezoelectric Low power Very large Kyser et al crystal such as consumption area required for U.S. Pat. No. 3,946,398 lead lanthanum Many ink actuator Zoltan U.S. Pat. No. zirconate (PZT) is types can be Difficult to 3,683,212 electrically used integrate with 1973 Stemme activated, and Fast operation electronics U.S. Pat. No. 3,747,120 either expands, High High voltage Epson Stylus shears, or bends to efficiency drive transistors Tektronix apply pressure to required IJ04 the ink, ejecting Full drops. pagewidth print heads impractical due to actuator size Requires electrical poling in high field strengths during manufacture Electrostrictive An electric field is Low power Low Seiko Epson, used to activate consumption maximum strain Usui et all JP electrostriction in Many ink (approx. 0.01%) 253401/96 relaxor materials types can be Large area IJ04 such as lead used required for lanthanum Low thermal actuator due to zirconate titanate expansion low strain (PLZT) or lead Electric field Response magnesium strength required speed is niobate (PMN). (approx. 3.5 V/μm) marginal (~10 μs) can be High voltage generated drive transistors without required difficulty Full Does not pagewidth print require electrical heads poling impractical due to actuator size Ferroelectric An electric field is Low power Difficult to IJ04 used to induce a consumption integrate with phase transition Many ink electronics between the types can be Unusual antiferroelectric used materials such as (AFE) and Fast operation PLZSnT are ferroelectric (FE) (<1 μs) required phase. Perovskite Relatively Actuators materials such as high longitudinal require a large tin modified lead strain area lanthanum High zirconate titanate efficiency (PLZSnT) exhibit Electric field large strains of up strength of to 1% associated around 3 V/μm with the AFE to can be readily FE phase provided transition. Electrostatic Conductive plates Low power Difficult to IJ02, IJ04 plates are separated by a consumption operate compressible or Many ink electrostatic fluid dielectric types can be devices in an (usually air). Upon used aqueous application of a Fast operation environment voltage, the plates The attract each other electrostatic and displace ink, actuator will causing drop normally need to ejection. The be separated conductive plates from the ink may be in a comb Very large or honeycomb area required to structure, or achieve high stacked to increase forces the surface area High voltage and therefore the drive transistors force. may be required Full pagewidth print heads are not competitive due to actuator size Electrostatic A strong electric Low current High voltage 1989 Saito et pull field is applied to consumption required al, U.S. Pat. No. on ink the ink, whereupon Low May be 4,799,068 electrostatic temperature damaged by 1989 Miura et attraction sparks due to air al, U.S. Pat. No. accelerates the ink breakdown 4,810,954 towards the print Required field Tone-jet medium. strength increases as the drop size decreases High voltage drive transistors required Electrostatic field attracts dust Permanent An electromagnet Low power Complex IJ07, IJ10 magnet directly attracts a consumption fabrication electromagnetic permanent magnet, Many ink Permanent displacing ink and types can be magnetic causing drop used material such as ejection. Rare Fast operation Neodymium Iron earth magnets with High Boron (NdFeB) a field strength efficiency required. around 1 Tesla can Easy High local be used. Examples extension from currents required are: Samarium single nozzles to Copper Cobalt (SaCo) and pagewidth print metalization magnetic materials heads should be used in the neodymium for long iron boron family electromigration (NdFeB, lifetime and low NdDyFeBNb, resistivity NdDyFeB, etc) Pigmented inks are usually infeasible Operating temperature limited to the Curie temperature (around 540 K) Soft A solenoid Low power Complex IJ01, IJ05, magnetic induced a consumption fabrication IJ08, IJ10, IJ12, core magnetic field in a Many ink Materials not IJ14, IJ15, IJ17 electromagnetic soft magnetic core types can be usually present or yoke fabricated used in a CMOS fab from a ferrous Fast operation such as NiFe, material such as High CoNiFe, or CoFe electroplated iron efficiency are required alloys such as Easy High local CoNiFe [1], CoFe, extension from currents required or NiFe alloys. single nozzles to Copper Typically, the soft pagewidth print metalization magnetic material heads should be used is in two parts, for long which are electromigration normally held lifetime and low apart by a spring. resistivity When the solenoid Electroplating is actuated, the two is required parts attract, High displacing the ink. saturation flux density is required (2.0-2.1 T is achievable with CoNiFe [1]) Lorenz The Lorenz force Low power Force acts as a IJ06, IJ11, force acting on a current consumption twisting motion IJ13, IJ16 carrying wire in a Many ink Typically, magnetic field is types can be only a quarter of utilized. used the solenoid This allows the Fast operation length provides magnetic field to High force in a useful be supplied efficiency direction externally to the Easy High local print head, for extension from currents required example with rare single nozzles to Copper earth permanent pagewidth print metalization magnets. heads should be used Only the current for long carrying wire need electromigration be fabricated on lifetime and low the print-head, resistivity simplifying Pigmented materials inks are usually requirements. infeasible Magnetostriction The actuator uses Many ink Force acts as a Fischenbeck, the giant types can be twisting motion U.S. Pat. No. 4,032,929 magnetostrictive used Unusual IJ25 effect of materials Fast operation materials such as such as Terfenol-D Easy Terfenol-D are (an alloy of extension from required terbium, single nozzles to High local dysprosium and pagewidth print currents required iron developed at heads Copper the Naval High force is metalization Ordnance available should be used Laboratory, hence for long Ter-Fe-NOL). For electromigration best efficiency, the lifetime and low actuator should be resistivity pre-stressed to Pre-stressing approx. 8 MPa. may be required Surface Ink under positive Low power Requires Silverbrook, tension pressure is held in consumption supplementary EP 0771 658 A2 reduction a nozzle by surface Simple force to effect and related tension. The construction drop separation patent surface tension of No unusual Requires applications the ink is reduced materials special ink below the bubble required in surfactants threshold, causing fabrication Speed may be the ink to egress High limited by from the nozzle. efficiency surfactant Easy properties extension from single nozzles to pagewidth print heads Viscosity The ink viscosity Simple Requires Silverbrook, reduction is locally reduced construction supplementary EP 0771 658 A2 to select which No unusual force to effect and related drops are to be materials drop separation patent ejected. A required in Requires applications viscosity reduction fabrication special ink can be achieved Easy viscosity electrothermally extension from properties with most inks, but single nozzles to High speed is special inks can be pagewidth print difficult to engineered for a heads achieve 100:1 viscosity Requires reduction. oscillating ink pressure A high temperature difference (typically 80 degrees) is required Acoustic An acoustic wave Can operate Complex 1993 is generated and without a nozzle drive circuitry Hadimioglu et focussed upon the plate Complex al, EUP 550,192 drop ejection fabrication 1993 Elrod et region. Low al, EUP 572,220 efficiency Poor control of drop position Poor control of drop volume Thermoelastic An actuator which Low power Efficient IJ03, IJ09, bend relies upon consumption aqueous IJ17, IJ18, IJ19, actuator differential Many ink operation IJ20, IJ21, IJ22, thermal expansion types can be requires a IJ23, IJ24, IJ27, upon Joule heating used thermal insulator IJ28, IJ29, IJ30, is used. Simple planar on the hot side IJ31, IJ32, IJ33, fabrication Corrosion IJ34, IJ35, IJ36, Small chip prevention can IJ37, IJ38, IJ39, area required for be difficult IJ40, IJ41 each actuator Pigmented Fast operation inks may be High infeasible, as efficiency pigment particles CMOS may jam the compatible bend actuator voltages and currents Standard MEMS processes can be used Easy extension from single nozzles to pagewidth print heads High CTE A material with a High force Requires IJ09, IJ17, thermoelastic very high can be generated special material IJ18, IJ20, IJ21, actuator coefficient of Three (e.g. PTFE) IJ22, IJ23, IJ24, thermal expansion methods of Requires a IJ27, IJ28, IJ29, (CTE) such as PTFE deposition PTFE deposition IJ30, IJ31, IJ42, polytetrafluoroethylene are under process, which is IJ43, IJ44 (PTFE) is development: not yet standard used. As high CTE chemical vapor in ULSI fabs materials are deposition PTFE usually non- (CVD), spin deposition conductive, a coating, and cannot be heater fabricated evaporation followed with from a conductive PTFE is a high temperature material is candidate for (above 350° C.) incorporated. A 50 μm low dielectric processing long PTFE constant Pigmented bend actuator with insulation in inks may be polysilicon heater ULSI infeasible, as and 15 mW power Very low pigment particles input can provide power may jam the 180 μN force and consumption bend actuator 10 μm deflection. Many ink Actuator motions types can be include: used Bend Simple planar Push fabrication Buckle Small chip Rotate area required for each actuator Fast operation High efficiency CMOS compatible voltages and currents Easy extension from single nozzles to pagewidth print heads Conductive A polymer with a High force Requires IJ24 polymer high coefficient of can be generated special materials thermoelastic thermal expansion Very low development actuator (such as PTFE) is power (High CTE doped with consumption conductive conducting Many ink polymer) substances to types can be Requires a increase its used PTFE deposition conductivity to Simple planar process, which is about 3 orders of fabrication not yet standard magnitude below Small chip in ULSI fabs that of copper. The area required for PTFE conducting each actuator deposition polymer expands Fast operation cannot be when resistively High followed with heated. efficiency high temperature Examples of CMOS (above 350° C.) conducting compatible processing dopants include: voltages and Evaporation Carbon nanotubes currents and CVD Metal fibers Easy deposition Conductive extension from techniques polymers such as single nozzles to cannot be used doped pagewidth print Pigmented polythiophene heads inks may be Carbon granules infeasible, as pigment particles may jam the bend actuator Shape A shape memory High force is Fatigue limits IJ26 memory alloy such as TiNi available maximum alloy (also known as (stresses of number of cycles Nitinol —Nickel hundreds of Low strain Titanium alloy MPa) (1%) is required developed at the Large strain is to extend fatigue Naval Ordnance available (more resistance Laboratory) is than 3%) Cycle rate thermally switched High limited by heat between its weak corrosion removal martensitic state resistance Requires and its high Simple unusual stiffness austenic construction materials (TiNi) state. The shape of Easy The latent the actuator in its extension from heat of martensitic state is single nozzles to transformation deformed relative pagewidth print must be to the austenic heads provided shape. The shape Low voltage High current change causes operation operation ejection of a drop. Requires pre- stressing to distort the martensitic state Linear Linear magnetic Linear Requires IJ12 Magnetic actuators include Magnetic unusual Actuator the Linear actuators can be semiconductor Induction Actuator constructed with materials such as (LIA), Linear high thrust, long soft magnetic Permanent Magnet travel, and high alloys (e.g. Synchronous efficiency using CoNiFe) Actuator planar Some varieties (LPMSA), Linear semiconductor also require Reluctance fabrication permanent Synchronous techniques magnetic Actuator (LRSA), Long actuator materials such as Linear Switched travel is Neodymium iron Reluctance available boron (NdFeB) Actuator (LSRA), Medium force Requires and the Linear is available complex multi- Stepper Actuator Low voltage phase drive (LSA). operation circuitry High current operation

BASIC OPERATION MODE Description Advantages Disadvantages Examples Actuator This is the Simple Drop Thermal ink directly simplest mode of operation repetition rate is jet pushes operation: the No external usually limited Piezoelectric ink actuator directly fields required to around 10 kHz. ink jet supplies sufficient Satellite drops However, IJ01, IJ02, kinetic energy to can be avoided if this is not IJ03, IJ04, IJ05, expel the drop. drop velocity is fundamental to IJ06, IJ07, IJ09, The drop must less than 4 m/s the method, but IJ11, IJ12, IJ14, have a sufficient Can be is related to the IJ16, IJ20, IJ22, velocity to efficient, refill method IJ23, IJ24, IJ25, overcome the depending upon normally used IJ26, IJ27, IJ28, surface tension. the actuator used All of the drop IJ29, IJ30, IJ31, kinetic energy IJ32, IJ33, IJ34, must be IJ35, IJ36, IJ37, provided by the IJ38, IJ39, IJ40, actuator IJ41, IJ42, IJ43, Satellite drops IJ44 usually form if drop velocity is greater than 4.5 m/s Proximity The drops to be Very simple Requires close Silverbrook, printed are print head proximity EP 0771 658 A2 selected by some fabrication can between the and related manner (e.g. be used print head and patent thermally induced The drop the print media applications surface tension selection means or transfer roller reduction of does not need to May require pressurized ink). provide the two print heads Selected drops are energy required printing alternate separated from the to separate the rows of the ink in the nozzle drop from the image by contact with the nozzle Monolithic print medium or a color print heads transfer roller. are difficult Electrostatic The drops to be Very simple Requires very Silverbrook, pull printed are print head high electrostatic EP 0771 658 A2 on ink selected by some fabrication can field and related manner (e.g. be used Electrostatic patent thermally induced The drop field for small applications surface tension selection means nozzle sizes is Tone-Jet reduction of does not need to above air pressurized ink). provide the breakdown Selected drops are energy required Electrostatic separated from the to separate the field may attract ink in the nozzle drop from the dust by a strong electric nozzle field. Magnetic The drops to be Very simple Requires Silverbrook, pull on printed are print head magnetic ink EP 0771 658 A2 ink selected by some fabrication can Ink colors and related manner (e.g. be used other than black patent thermally induced The drop are difficult applications surface tension selection means Requires very reduction of does not need to high magnetic pressurized ink). provide the fields Selected drops are energy required separated from the to separate the ink in the nozzle drop from the by a strong nozzle magnetic field acting on the magnetic ink. Shutter The actuator High speed Moving parts IJ13, IJ17, moves a shutter to (>50 kHz) are required IJ21 block ink flow to operation can be Requires ink the nozzle. The ink achieved due to pressure pressure is pulsed reduced refill modulator at a multiple of the time Friction and drop ejection Drop timing wear must be frequency. can be very considered accurate Stiction is The actuator possible energy can be very low Shuttered The actuator Actuators with Moving parts IJ08, IJ15, grill moves a shutter to small travel can are required IJ18, IJ19 block ink flow be used Requires ink through a grill to Actuators with pressure the nozzle. The small force can modulator shutter movement be used Friction and need only be equal High speed wear must be to the width of the (>50 kHz) considered grill holes. operation can be Stiction is achieved possible Pulsed A pulsed magnetic Extremely low Requires an IJ10 magnetic field attracts an energy operation external pulsed pull on ‘ink pusher’ at the is possible magnetic field ink drop ejection No heat Requires pusher frequency. An dissipation special materials actuator controls a problems for both the catch, which actuator and the prevents the ink ink pusher pusher from Complex moving when a construction drop is not to be ejected.

Description Advantages Disadvantages Examples AUXILIARY MECHANISM (APPLIED TO ALL NOZZLES) None The actuator Simplicity of Drop ejection Most ink jets, directly fires the construction energy must be including ink drop, and there Simplicity of supplied by piezoelectric and is no external field operation individual nozzle thermal bubble. or other Small physical actuator IJ01, IJ02, mechanism size IJ03, IJ04, IJ05, required. IJ07, IJ09, IJ11, IJ12, IJ14, IJ20, IJ22, IJ23, IJ24, IJ25, IJ26, IJ27, IJ28, IJ29, IJ30, IJ31, IJ32, IJ33, IJ34, IJ35, IJ36, IJ37, IJ38, IJ39, IJ40, IJ41, IJ42, IJ43, IJ44 Oscillating The ink pressure Oscillating ink Requires Silverbrook, ink oscillates, pressure can external ink EP 0771 658 A2 pressure providing much of provide a refill pressure and related (including the drop ejection pulse, allowing oscillator patent acoustic energy. The higher operating Ink pressure applications stimulation) actuator selects speed phase and IJ08, IJ13, which drops are to The actuators amplitude must IJ15, IJ17, IJ18, be fired by may operate be carefully IJ19, IJ21 selectively with much lower controlled blocking or energy Acoustic enabling nozzles. Acoustic reflections in the The ink pressure lenses can be ink chamber oscillation may be used to focus the must be achieved by sound on the designed for vibrating the print nozzles head, or preferably by an actuator in the ink supply. Media The print head is Low power Precision Silverbrook, proximity placed in close High accuracy assembly EP 0771 658 A2 proximity to the Simple print required and related print medium. head Paper fibers patent Selected drops construction may cause applications protrude from the problems print head further Cannot print than unselected on rough drops, and contact substrates the print medium. The drop soaks into the medium fast enough to cause drop separation. Transfer Drops are printed High accuracy Bulky Silverbrook, roller to a transfer roller Wide range of Expensive EP 0771 658 A2 instead of straight print substrates Complex and related to the print can be used construction patent medium. A Ink can be applications transfer roller can dried on the Tektronix hot also be used for transfer roller melt proximity drop piezoelectric ink separation. jet Any of the IJ series Electrostatic An electric field is Low power Field strength Silverbrook, used to accelerate Simple print required for EP 0771 658 A2 selected drops head separation of and related towards the print construction small drops is patent medium. near or above air applications breakdown Tone-Jet Direct A magnetic field is Low power Requires Silverbrook, magnetic used to accelerate Simple print magnetic ink EP 0771 658 A2 field selected drops of head Requires and related magnetic ink construction strong magnetic patent towards the print field applications medium. Cross The print head is Does not Requires IJ06, IJ16 magnetic placed in a require magnetic external magnet field constant magnetic materials to be Current field. The Lorenz integrated in the densities may be force in a current print head high, resulting in carrying wire is manufacturing electromigration used to move the process problems actuator. Pulsed A pulsed magnetic Very low Complex print IJ10 magnetic field is used to power operation head field cyclically attract a is possible construction paddle, which Small print Magnetic pushes on the ink. head size materials A small actuator required in print moves a catch, head which selectively prevents the paddle from moving. ACTUATOR AMPLIFICATION OR MODIFICATION METHOD None No actuator Operational Many actuator Thermal mechanical simplicity mechanisms Bubble Ink jet amplification is have insufficient IJ01, IJ02, used. The actuator travel, or IJ06, IJ07, IJ16, directly drives the insufficient IJ25, IJ26 drop ejection force, to process. efficiently drive the drop ejection process Differential An actuator Provides High stresses Piezoelectric expansion material expands greater travel in are involved IJ03, IJ09, bend more on one side a reduced print Care must be IJ17, IJ18, IJ19, actuator than on the other. head area taken that the IJ20, IJ21, IJ22, The expansion materials do not IJ23, IJ24, IJ27, may be thermal, delaminate IJ29, IJ30, IJ31, piezoelectric, Residual bend IJ32, IJ33, IJ34, magnetostrictive, resulting from IJ35, IJ36, IJ37, or other high temperature IJ38, IJ39, IJ42, mechanism. The or high stress IJ43, IJ44 bend actuator during formation converts a high force low travel actuator mechanism to high travel, lower force mechanism. Transient A trilayer bend Very good High stresses IJ40, IJ41 bend actuator where the temperature are involved actuator two outside layers stability Care must be are identical. This High speed, as taken that the cancels bend due a new drop can materials do not to ambient be fired before delaminate temperature and heat dissipates residual stress. The Cancels actuator only residual stress of responds to formation transient heating of one side or the other. Reverse The actuator loads Better Fabrication IJ05, IJ11 spring a spring. When the coupling to the complexity actuator is turned ink High stress in off, the spring the spring releases. This can reverse the force/distance curve of the actuator to make it compatible with the force/time requirements of the drop ejection. Actuator A series of thin Increased Increased Some stack actuators are travel fabrication piezoelectric ink stacked. This can Reduced drive complexity jets be appropriate voltage Increased IJ04 where actuators possibility of require high short circuits due electric field to pinholes strength, such as electrostatic and piezoelectric actuators. Multiple Multiple smaller Increases the Actuator IJ12, IJ13, actuators actuators are used force available forces may not IJ18, IJ20, IJ22, simultaneously to from an actuator add linearly, IJ28, IJ42, IJ43 move the ink. Each Multiple reducing actuator need actuators can be efficiency provide only a positioned to portion of the control ink flow force required. accurately Linear A linear spring is Matches low Requires print IJ15 Spring used to transform a travel actuator head area for the motion with small with higher spring travel and high travel force into a longer requirements travel, lower force Non-contact motion. method of motion transformation Coiled A bend actuator is Increases Generally IJ17, IJ21, actuator coiled to provide travel restricted to IJ34, IJ35 greater travel in a Reduces chip planar reduced chip area. area implementations Planar due to extreme implementations fabrication are relatively difficulty in easy to fabricate. other orientations. Flexure A bend actuator Simple means Care must be IJ10, IJ19, bend has a small region of increasing taken not to IJ33 actuator near the fixture travel of a bend exceed the point, which flexes actuator elastic limit in much more readily the flexure area than the remainder Stress of the actuator. distribution is The actuator very uneven flexing is Difficult to effectively accurately model converted from an with finite even coiling to an element analysis angular bend, resulting in greater travel of the actuator tip. Catch The actuator Very low Complex IJ10 controls a small actuator energy construction catch. The catch Very small Requires either enables or actuator size external force disables movement Unsuitable for of an ink pusher pigmented inks that is controlled in a bulk manner. Gears Gears can be used Low force, Moving parts IJ13 to increase travel low travel are required at the expense of actuators can be Several duration. Circular used actuator cycles gears, rack and Can be are required pinion, ratchets, fabricated using More complex and other gearing standard surface drive electronics methods can be MEMS Complex used. processes construction Friction, friction, and wear are possible Buckle A buckle plate can Very fast Must stay S. Hirata et al, plate be used to change movement within elastic “An Ink-jet a slow actuator achievable limits of the Head Using into a fast motion. materials for Diaphragm It can also convert long device life Microactuator”, a high force, low High stresses Proc. IEEE travel actuator into involved MEMS, February a high travel, Generally 1996, pp 418-423. medium force high power IJ18, IJ27 motion. requirement Tapered A tapered Linearizes the Complex IJ14 magnetic magnetic pole can magnetic construction pole increase travel at force/distance the expense of curve force. Lever A lever and Matches low High stress IJ32, IJ36, fulcrum is used to travel actuator around the IJ37 transform a motion with higher fulcrum with small travel travel and high force into requirements a motion with Fulcrum area longer travel and has no linear lower force. The movement, and lever can also can be used for a reverse the fluid seal direction of travel. Rotary The actuator is High Complex IJ28 impeller connected to a mechanical construction rotary impeller. A advantage Unsuitable for small angular The ratio of pigmented inks deflection of the force to travel of actuator results in the actuator can a rotation of the be matched to impeller vanes, the nozzle which push the ink requirements by against stationary varying the vanes and out of number of the nozzle. impeller vanes Acoustic A refractive or No moving Large area 1993 lens diffractive (e.g. parts required Hadimioglu et zone plate) Only relevant al, EUP 550,192 acoustic lens is for acoustic ink 1993 Elrod et used to concentrate jets al, EUP 572,220 sound waves. Sharp A sharp point is Simple Difficult to Tone-jet conductive used to concentrate construction fabricate using point an electrostatic standard VLSI field. processes for a surface ejecting ink-jet Only relevant for electrostatic ink jets

ACTUATOR MOTION Description Advantages Disadvantages Examples Volume The volume of the Simple High energy is Hewlett- expansion actuator changes, construction in typically Packard Thermal pushing the ink in the case of required to Ink jet all directions. thermal ink jet achieve volume Canon expansion. This Bubblejet leads to thermal stress, cavitation, and kogation in thermal ink jet implementations Linear, The actuator Efficient High IJ01, IJ02, normal to moves in a coupling to ink fabrication IJ04, IJ07, IJ11, chip direction normal to drops ejected complexity may IJ14 surface the print head normal to the be required to surface. The surface achieve nozzle is typically perpendicular in the line of motion movement. Parallel to The actuator Suitable for Fabrication IJ12, IJ13, chip moves parallel to planar complexity IJ15, IJ33,, IJ34, surface the print head fabrication Friction IJ35, IJ36 surface. Drop Stiction ejection may still be normal to the surface. Membrane An actuator with a The effective Fabrication 1982 Howkins push high force but area of the complexity U.S. Pat. No. 4,459,601 small area is used actuator Actuator size to push a stiff becomes the Difficulty of membrane that is membrane area integration in a in contact with the VLSI process ink. Rotary The actuator Rotary levers Device IJ05, IJ08, causes the rotation may be used to complexity IJ13, IJ28 of some element, increase travel May have such a grill or Small chip friction at a pivot impeller area point requirements Bend The actuator bends A very small Requires the 1970 Kyser et when energized. change in actuator to be al U.S. Pat. No. This may be due to dimensions can made from at 3,946,398 differential be converted to a least two distinct 1973 Stemme thermal expansion, large motion. layers, or to have U.S. Pat. No. 3,747,120 piezoelectric a thermal IJ03, IJ09, expansion, difference across IJ10, IJ19, IJ23, magnetostriction, the actuator IJ24, IJ25, IJ29, or other form of IJ30, IJ31, IJ33, relative IJ34, IJ35 dimensional change. Swivel The actuator Allows Inefficient IJ06 swivels around a operation where coupling to the central pivot. This the net linear ink motion motion is suitable force on the where there are paddle is zero opposite forces Small chip applied to opposite area sides of the paddle, requirements e.g. Lorenz force. Straighten The actuator is Can be used Requires IJ26, IJ32 normally bent, and with shape careful balance straightens when memory alloys of stresses to energized. where the ensure that the austenic phase is quiescent bend is planar accurate Double The actuator bends One actuator Difficult to IJ36, IJ37, bend in one direction can be used to make the drops IJ38 when one element power two ejected by both is energized, and nozzles. bend directions bends the other Reduced chip identical. way when another size. A small element is Not sensitive efficiency loss energized. to ambient compared to temperature equivalent single bend actuators. Shear Energizing the Can increase Not readily 1985 Fishbeck actuator causes a the effective applicable to U.S. Pat. No. 4,584,590 shear motion in the travel of other actuator actuator material. piezoelectric mechanisms actuators Radial The actuator Relatively High force 1970 Zoltan constriction squeezes an ink easy to fabricate required U.S. Pat. No. 3,683,212 reservoir, forcing single nozzles Inefficient ink from a from glass Difficult to constricted nozzle. tubing as integrate with macroscopic VLSI processes structures Coil/ A coiled actuator Easy to Difficult to IJ17, IJ21, uncoil uncoils or coils fabricate as a fabricate for IJ34, IJ35 more tightly. The planar VLSI non-planar motion of the free process devices end of the actuator Small area Poor out-of- ejects the ink. required, plane stiffness therefore low cost Bow The actuator bows Can increase Maximum IJ16, IJ18, (or buckles) in the the speed of travel is IJ27 middle when travel constrained energized. Mechanically High force rigid required Push-Pull Two actuators The structure Not readily IJ18 control a shutter. is pinned at both suitable for ink One actuator pulls ends, so has a jets which the shutter, and the high out-of- directly push the other pushes it. plane rigidity ink Curl A set of actuators Good fluid Design IJ20, IJ42 inwards curl inwards to flow to the complexity reduce the volume region behind of ink that they the actuator enclose. increases efficiency Curl A set of actuators Relatively Relatively IJ43 outwards curl outwards, simple large chip area pressurizing ink in construction a chamber surrounding the actuators, and expelling ink from a nozzle in the chamber. Iris Multiple vanes High High IJ22 enclose a volume efficiency fabrication of ink. These Small chip complexity simultaneously area Not suitable rotate, reducing for pigmented the volume inks between the vanes. Acoustic The actuator The actuator Large area 1993 vibration vibrates at a high can be required for Hadimioglu et frequency. physically efficient al, EUP 550,192 distant from the operation at 1993 Elrod et ink useful al, EUP 572,220 frequencies Acoustic coupling and crosstalk Complex drive circuitry Poor control of drop volume and position None In various ink jet No moving Various other Silverbrook, designs the parts tradeoffs are EP 0771 658 A2 actuator does not required to and related move. eliminate patent moving parts applications Tone-jet

NOZZLE REFILL METHOD Description Advantages Disadvantages Examples Surface This is the normal Fabrication Low speed Thermal ink tension way that ink jets simplicity Surface jet are refilled. After Operational tension force Piezoelectric the actuator is simplicity relatively small ink jet energized, it compared to IJ01-IJ07, typically returns actuator force IJ10-IJ14, IJ16, rapidly to its Long refill IJ20, IJ22-IJ45 normal position. time usually This rapid return dominates the sucks in air total repetition through the nozzle rate opening. The ink surface tension at the nozzle then exerts a small force restoring the meniscus to a minimum area. This force refills the nozzle. Shuttered Ink to the nozzle High speed Requires IJ08, IJ13, oscillating chamber is Low actuator common ink IJ15, IJ17, IJ18, ink provided at a energy, as the pressure IJ19, IJ21 pressure pressure that actuator need oscillator oscillates at twice only open or May not be the drop ejection close the shutter, suitable for frequency. When a instead of pigmented inks drop is to be ejecting the ink ejected, the shutter drop is opened for 3 half cycles: drop ejection, actuator return, and refill. The shutter is then closed to prevent the nozzle chamber emptying during the next negative pressure cycle. Refill After the main High speed, as Requires two IJ09 actuator actuator has the nozzle is independent ejected a drop a actively refilled actuators per second (refill) nozzle actuator is energized. The refill actuator pushes ink into the nozzle chamber. The refill actuator returns slowly, to prevent its return from emptying the chamber again. Positive The ink is held a High refill Surface spill Silverbrook, ink slight positive rate, therefore a must be EP 0771 658 A2 pressure pressure. After the high drop prevented and related ink drop is ejected, repetition rate is Highly patent the nozzle possible hydrophobic applications chamber fills print head Alternative quickly as surface surfaces are for:, IJ01-IJ07, tension and ink required IJ10-IJ14, IJ16, pressure both IJ20, IJ22-IJ45 operate to refill the nozzle.

METHOD OF RESTRICTING BACK-FLOW THROUGH INLET Description Advantages Disadvantages Examples Long inlet The ink inlet Design Restricts refill Thermal ink channel channel to the simplicity rate jet nozzle chamber is Operational May result in Piezoelectric made long and simplicity a relatively large ink jet relatively narrow, Reduces chip area IJ42, IJ43 relying on viscous crosstalk Only partially drag to reduce effective inlet back-flow. Positive The ink is under a Drop selection Requires a Silverbrook, ink positive pressure, and separation method (such as EP 0771 658 A2 pressure so that in the forces can be a nozzle rim or and related quiescent state reduced effective patent some of the ink Fast refill time hydrophobizing, applications drop already or both) to Possible protrudes from the prevent flooding operation of the nozzle. of the ejection following: IJ01-IJ07, This reduces the surface of the IJ09-IJ12, pressure in the print head. IJ14, IJ16, IJ20, nozzle chamber IJ22,, IJ23-IJ34, which is required IJ36-IJ41, IJ44 to eject a certain volume of ink. The reduction in chamber pressure results in a reduction in ink pushed out through the inlet. Baffle One or more The refill rate Design HP Thermal baffles are placed is not as complexity Ink Jet in the inlet ink restricted as the May increase Tektronix flow. When the long inlet fabrication piezoelectric ink actuator is method. complexity (e.g. jet energized, the Reduces Tektronix hot rapid ink crosstalk melt movement creates Piezoelectric eddies which print heads). restrict the flow through the inlet. The slower refill process is unrestricted, and does not result in eddies. Flexible In this method Significantly Not applicable Canon flap recently disclosed reduces back- to most ink jet restricts by Canon, the flow for edge- configurations inlet expanding actuator shooter thermal Increased (bubble) pushes on ink jet devices fabrication a flexible flap that complexity restricts the inlet. Inelastic deformation of polymer flap results in creep over extended use Inlet filter A filter is located Additional Restricts refill IJ04, IJ12, between the ink advantage of ink rate IJ24, IJ27, IJ29, inlet and the filtration May result in IJ30 nozzle chamber. Ink filter may complex The filter has a be fabricated construction multitude of small with no holes or slots, additional restricting ink process steps flow. The filter also removes particles which may block the nozzle. Small The ink inlet Design Restricts refill IJ02, IJ37, inlet channel to the simplicity rate IJ44 compared nozzle chamber May result in to nozzle has a substantially a relatively large smaller cross chip area section than that of Only partially the nozzle, effective resulting in easier ink egress out of the nozzle than out of the inlet. Inlet A secondary Increases Requires IJ09 shutter actuator controls speed of the ink- separate refill the position of a jet print head actuator and shutter, closing off operation drive circuit the ink inlet when the main actuator is energized. The inlet The method avoids Back-flow Requires IJ01, IJ03, is located the problem of problem is careful design to IJ05, IJ06, IJ07, behind inlet back-flow by eliminated minimize the IJ10, IJ11, IJ14, the ink- arranging the ink- negative IJ16, IJ22, IJ23, pushing pushing surface of pressure behind IJ25, IJ28, IJ31, surface the actuator the paddle IJ32, IJ33, IJ34, between the inlet IJ35, IJ36, IJ39, and the nozzle. IJ40, IJ41 Part of The actuator and a Significant Small increase IJ07, IJ20, the wall of the ink reductions in in fabrication IJ26, IJ38 actuator chamber are back-flow can be complexity moves to arranged so that achieved shut off the motion of the Compact the inlet actuator closes off designs possible the inlet. Nozzle In some Ink back-flow None related Silverbrook, actuator configurations of problem is to ink back-flow EP 0771 658 A2 does not ink jet, there is no eliminated on actuation and related result in expansion or patent ink back- movement of an applications flow actuator which Valve-jet may cause ink Tone-jet back-flow through the inlet.

NOZZLE CLEARING METHOD Description Advantages Disadvantages Examples Normal All of the nozzles No added May not be Most ink jet nozzle are fired complexity on sufficient to systems firing periodically, the print head displace dried IJ01, IJ02, before the ink has ink IJ03, IJ04, IJ05, a chance to dry. IJ06, IJ07, IJ09, When not in use IJ10, IJ11, IJ12, the nozzles are IJ14, IJ16, IJ20, sealed (capped) IJ22, IJ23, IJ24, against air. IJ25, IJ26, IJ27, The nozzle firing IJ28, IJ29, IJ30, is usually IJ31, IJ32, IJ33, performed during a IJ34, IJ36, IJ37, special clearing IJ38, IJ39, IJ40,, cycle, after first IJ41, IJ42, IJ43, moving the print IJ44,, IJ45 head to a cleaning station. Extra In systems which Can be highly Requires Silverbrook, power to heat the ink, but do effective if the higher drive EP 0771 658 A2 ink heater not boil it under heater is voltage for and related normal situations, adjacent to the clearing patent nozzle clearing can nozzle May require applications be achieved by larger drive over-powering the transistors heater and boiling ink at the nozzle. Rapid The actuator is Does not Effectiveness May be used succession fired in rapid require extra depends with: IJ01, IJ02, of succession. In drive circuits on substantially IJ03, IJ04, IJ05, actuator some the print head upon the IJ06, IJ07, IJ09, pulses configurations, this Can be readily configuration of IJ10, IJ11, IJ14, may cause heat controlled and the ink jet nozzle IJ16, IJ20, IJ22, build-up at the initiated by IJ23, IJ24, IJ25, nozzle which boils digital logic IJ27, IJ28, IJ29, the ink, clearing IJ30, IJ31, IJ32, the nozzle. In other IJ33, IJ34, IJ36, situations, it may IJ37, IJ38, IJ39, cause sufficient IJ40, IJ41, IJ42, vibrations to IJ43, IJ44, IJ45 dislodge clogged nozzles. Extra Where an actuator A simple Not suitable May be used power to is not normally solution where where there is a with: IJ03, IJ09, ink driven to the limit applicable hard limit to IJ16, IJ20, IJ23, pushing of its motion, actuator IJ24, IJ25, IJ27, actuator nozzle clearing movement IJ29, IJ30, IJ31, may be assisted by IJ32, IJ39, IJ40, providing an IJ41, IJ42, IJ43, enhanced drive IJ44, IJ45 signal to the actuator. Acoustic An ultrasonic A high nozzle High IJ08, IJ13, resonance wave is applied to clearing implementation IJ15, IJ17, IJ18, the ink chamber. capability can be cost if system IJ19, IJ21 This wave is of an achieved does not already appropriate May be include an amplitude and implemented at acoustic actuator frequency to cause very low cost in sufficient force at systems which the nozzle to clear already include blockages. This is acoustic easiest to achieve actuators if the ultrasonic wave is at a resonant frequency of the ink cavity. Nozzle A microfabricated Can clear Accurate Silverbrook, clearing plate is pushed severely clogged mechanical EP 0771 658 A2 plate against the nozzles alignment is and related nozzles. The plate required patent has a post for Moving parts applications every nozzle. A are required post moves There is risk through each of damage to the nozzle, displacing nozzles dried ink. Accurate fabrication is required Ink The pressure of the May be Requires May be used pressure ink is temporarily effective where pressure pump with all IJ series pulse increased so that other methods or other pressure ink jets ink streams from cannot be used actuator all of the nozzles. Expensive This may be used Wasteful of in conjunction ink with actuator energizing. Print A flexible ‘blade’ Effective for Difficult to Many ink jet head is wiped across the planar print head use if print head systems wiper print head surface. surfaces surface is non- The blade is Low cost planar or very usually fabricated fragile from a flexible Requires polymer, e.g. mechanical parts rubber or synthetic Blade can elastomer. wear out in high volume print systems Separate A separate heater Can be Fabrication Can be used ink is provided at the effective where complexity with many IJ boiling nozzle although other nozzle series ink jets heater the normal drop e- clearing methods ection mechanism cannot be used does not require it. Can be The heaters do not implemented at require individual no additional drive circuits, as cost in some ink many nozzles can jet be cleared configurations simultaneously, and no imaging is required.

NOZZLE PLATE CONSTRUCTION Description Advantages Disadvantages Examples Electroformed A nozzle plate is Fabrication High Hewlett nickel separately simplicity temperatures and Packard Thermal fabricated from pressures are Ink jet electroformed required to bond nickel, and bonded nozzle plate to the print head Minimum chip. thickness constraints Differential thermal expansion Laser Individual nozzle No masks Each hole Canon ablated or holes are ablated required must be Bubblejet drilled by an intense UV Can be quite individually 1988 Sercel et polymer laser in a nozzle fast formed al., SPIE, Vol. plate, which is Some control Special 998 Excimer typically a over nozzle equipment Beam polymer such as profile is required Applications, pp. polyimide or possible Slow where 76-83 polysulphone Equipment there are many 1993 required is thousands of Watanabe et al., relatively low nozzles per print U.S. Pat. No. 5,208,604 cost head May produce thin burrs at exit holes Silicon A separate nozzle High accuracy Two part K. Bean, micromachined plate is is attainable construction IEEE micromachined High cost Transactions on from single crystal Requires Electron silicon, and precision Devices, Vol. bonded to the print alignment ED-25, No. 10, head wafer. Nozzles may 1978, pp 1185-1195 be clogged by Xerox 1990 adhesive Hawkins et al., U.S. Pat. No. 4,899,181 Glass Fine glass No expensive Very small 1970 Zoltan capillaries capillaries are equipment nozzle sizes are U.S. Pat. No. 3,683,212 drawn from glass required difficult to form tubing. This Simple to Not suited for method has been make single mass production used for making nozzles individual nozzles, but is difficult to use for bulk manufacturing of print heads with thousands of nozzles. Monolithic, The nozzle plate is High accuracy Requires Silverbrook, surface deposited as a (<1 μm) sacrificial layer EP 0771 658 A2 micromachined layer using Monolithic under the nozzle and related using standard VLSI Low cost plate to form the patent VLSI deposition Existing nozzle chamber applications lithographic techniques. processes can be Surface may IJ01, IJ02, processes Nozzles are etched used be fragile to the IJ04, IJ11, IJ12, in the nozzle plate touch IJ17, IJ18, IJ20, using VLSI IJ22, IJ24, IJ27, lithography and IJ28, IJ29, IJ30, etching. IJ31, IJ32, IJ33, IJ34, IJ36, IJ37, IJ38, IJ39, IJ40, IJ41, IJ42, IJ43, IJ44 Monolithic, The nozzle plate is High accuracy Requires long IJ03, IJ05, etched a buried etch stop (<1 μm) etch times IJ06, IJ07, IJ08, through in the wafer. Monolithic Requires a IJ09, IJ10, IJ13, substrate Nozzle chambers Low cost support wafer IJ14, IJ15, IJ16, are etched in the No differential IJ19, IJ21, IJ23, front of the wafer, expansion IJ25, IJ26 and the wafer is thinned from the back side. Nozzles are then etched in the etch stop layer. No nozzle Various methods No nozzles to Difficult to Ricoh 1995 plate have been tried to become clogged control drop Sekiya et al U.S. Pat. No. eliminate the position 5,412,413 nozzles entirely, to accurately 1993 prevent nozzle Crosstalk Hadimioglu et al clogging. These problems EUP 550,192 include thermal 1993 Elrod et bubble al EUP 572,220 mechanisms and acoustic lens mechanisms Trough Each drop ejector Reduced Drop firing IJ35 has a trough manufacturing direction is through which a complexity sensitive to paddle moves. Monolithic wicking. There is no nozzle plate. Nozzle slit The elimination of No nozzles to Difficult to 1989 Saito et instead of nozzle holes and become clogged control drop al U.S. Pat. No. individual replacement by a position 4,799,068 nozzles slit encompassing accurately many actuator Crosstalk positions reduces problems nozzle clogging, but increases crosstalk due to ink surface waves

DROP EJECTION DIRECTION Description Advantages Disadvantages Examples Edge Ink flow is along Simple Nozzles Canon (‘edge the surface of the construction limited to edge Bubblejet 1979 shooter’) chip, and ink drops No silicon High Endo et al GB are ejected from etching required resolution is patent 2,007,162 the chip edge. Good heat difficult Xerox heater- sinking via Fast color in-pit 1990 substrate printing requires Hawkins et al Mechanically one print head U.S. Pat. No. 4,899,181 strong per color Tone-jet Ease of chip handing Surface Ink flow is along No bulk Maximum ink Hewlett- (‘roof the surface of the silicon etching flow is severely Packard TIJ shooter’) chip, and ink drops required restricted 1982 Vaught et are ejected from Silicon can al U.S. Pat. No. the chip surface, make an 4,490,728 normal to the effective heat IJ02, IJ11, plane of the chip. sink IJ12, IJ20, IJ22 Mechanical strength Through Ink flow is through High ink flow Requires bulk Silverbrook, chip, the chip, and ink Suitable for silicon etching EP 0771 658 A2 forward drops are ejected pagewidth print and related (‘up from the front heads patent shooter’) surface of the chip. High nozzle applications packing density IJ04, IJ17, therefore low IJ18, IJ24, IJ27-IJ45 manufacturing cost Through Ink flow is through High ink flow Requires IJ01, IJ03, chip, the chip, and ink Suitable for wafer thinning IJ05, IJ06, IJ07, reverse drops are ejected pagewidth print Requires IJ08, IJ09, IJ10, (‘down from the rear heads special handling IJ13, IJ14, IJ15, shooter’) surface of the chip. High nozzle during IJ16, IJ19, IJ21, packing density manufacture IJ23, IJ25, IJ26 therefore low manufacturing cost Through Ink flow is through Suitable for Pagewidth Epson Stylus actuator the actuator, which piezoelectric print heads Tektronix hot is not fabricated as print heads require several melt part of the same thousand piezoelectric ink substrate as the connections to jets drive transistors. drive circuits Cannot be manufactured in standard CMOS fabs Complex assembly required

INK TYPE Description Advantages Disadvantages Examples Aqueous, Water based ink Environmentally Slow drying Most existing dye which typically friendly Corrosive ink jets contains: water, No odor Bleeds on All IJ series dye, surfactant, paper ink jets humectant, and May Silverbrook, biocide. strikethrough EP 0771 658 A2 Modern ink dyes Cockles paper and related have high water- patent fastness, light applications fastness Aqueous, Water based ink Environmentally Slow drying IJ02, IJ04, pigment which typically friendly Corrosive IJ21, IJ26, IJ27, contains: water, No odor Pigment may IJ30 pigment, Reduced bleed clog nozzles Silverbrook, surfactant, Reduced Pigment may EP 0771 658 A2 humectant, and wicking clog actuator and related biocide. Reduced mechanisms patent Pigments have an strikethrough Cockles paper applications advantage in Piezoelectric reduced bleed, ink-jets wicking and Thermal ink strikethrough. jets (with significant restrictions) Methyl MEK is a highly Very fast Odorous All IJ series Ethyl volatile solvent drying Flammable ink jets Ketone used for industrial Prints on (MEK) printing on various difficult surfaces substrates such such as aluminum as metals and cans. plastics Alcohol Alcohol based inks Fast drying Slight odor All IJ series (ethanol, can be used where Operates at Flammable ink jets 2-butanol, the printer must sub-freezing and operate at temperatures others) temperatures Reduced below the freezing paper cockle point of water. An Low cost example of this is in-camera consumer photographic printing. Phase The ink is solid at No drying High viscosity Tektronix hot change room temperature, time-ink Printed ink melt (hot melt) and is melted in instantly freezes typically has a piezoelectric ink the print head on the print ‘waxy’ feel jets before jetting. Hot medium Printed pages 1989 Nowak melt inks are Almost any may ‘block’ U.S. Pat. No. 4,820,346 usually wax based, print medium Ink All IJ series with a melting can be used temperature may ink jets point around 80° C. No paper be above the After jetting cockle occurs curie point of the ink freezes No wicking permanent almost instantly occurs magnets upon contacting No bleed Ink heaters the print medium occurs consume power or a transfer roller. No Long warm- strikethrough up time occurs Oil Oil based inks are High High All IJ series extensively used in solubility viscosity: this is ink jets offset printing. medium for a significant They have some dyes limitation for use advantages in Does not in ink jets, which improved cockle paper usually require a characteristics on Does not wick low viscosity. paper (especially through paper Some short no wicking or chain and multi- cockle). Oil branched oils soluble dies and have a pigments are sufficiently low required. viscosity. Slow drying Microemulsion A microemulsion Stops ink Viscosity All IJ series is a stable, self bleed higher than ink jets forming emulsion High dye water of oil, water, and solubility Cost is surfactant. The Water, oil, slightly higher characteristic drop and amphiphilic than water based size is less than soluble dies can ink 100 nm, and is be used High determined by the Can stabilize surfactant preferred curvature pigment concentration of the surfactant. suspensions required (around 5%) 

1. A printhead integrated circuit that comprises a substrate; an external surface having a number of ink ejection ports operatively directed at a printing medium, the surface and the substrate defining a plurality of ink chambers in fluid communication with respective ink ejection ports, said surface comprising: a plurality of petal formations radially positioned about each ink ejection port; a plurality of actuators, each located behind a petal formation distal from said port; and a plurality of heater structures each connected to an actuator, so that heating of the structures via an electrical current produces differential thermal expansion in said actuators which urges the formations into the ink chambers.
 2. The printhead integrated circuit of claim 1, wherein the actuators are manufactured from a polytetrafluoroethylene (PTFE) material and have an internal serpentine copper core which forms the heater structures.
 3. The printhead integrated circuit of claim 1, which includes a number of central arms radially positioned about the port between the petal formations to provide structural support for the formations.
 4. The printhead integrated circuit of claim 1, which defines a rim about the ejection port.
 5. The printhead integrated circuit of claim 1, wherein the actuators are manufactured from a material having a coefficient of thermal expansion sufficiently high so that the actuators can perform work when they expand.
 6. The printhead integrated circuit of claim 1, which includes an integrated layer of CMOS circuitry which drives the heater structures.
 7. The printhead integrated circuit of claim 6, which defines a number of vias through which the CMOS drive circuitry is connected to the heater structures. 